Calorex Pro-Pac Series Quick start guide

page 1
SD566252 ISSUE 48
Pro-Pac system
Pro-Pac 30/45/70/90/140M/MY
Owner installation manual (SD566252 issue 51)

2 SD566252 ISSUE 51
PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

CONTENTS
AIR/WATER HEAT PUMPS.........................................................4
THE HEAT PUMP CYCLE............................................................5
INSTALLATION. ...........................................................................6
1. SITING......................................................................................6
2. AIR FLOW................................................................................7
3. PLUMBING ..............................................................................8
4. DETERMINING WATER FLOW............................................ 10
5.0 ELECTROLYTIC CORROSION IN SWIMMING POOLS.. 11
5.1 ELECTRICAL (MACHINE WIRING AND SUPPLY).......... 12
6.0 REGULAR PLANNED MAINTENANCE ........................... 27
7.0 CONTROLS AND INDICATION LAMPS........................... 28
8.0 HEAT PUMP MALFUNCTION........................................... 30
9.0 DATA SHEETS.................................................................... 33
10.0 INSTALLATION DRAWINGS........................................... 37
11.0 WINTERISATION PROCEDURE..................................... 47
11.1 START UP PROCEDURE AFTER WINTERISATION ..... 47
12.0 WARRANTY CONDITIONS............................................. 48
13.0 REFRIGERATION DIAGRAMS........................................ 49
14.0 MACHINE RECORD LOG................................................ 51
HEALTH AND SAFETY WARNING
As e dehumidifier embodies electrical and rotational equipment, ONLY competent persons
should carry out any work on is type of machine.
(SEE GUARANTEE)
3
SD566252 ISSUE 51

AIR/WATER HEAT PUMPS
IMPORTANT NOTE
Danerm Ltd. is an ISO9001:2000 certified company.
All Calorex heat pumps are CE approved.
MODELS PRO-PAC 30/45/70/90/140
The Calorex Pro-Pac range of air/water heat pumps for
swimming pool applications consist of 5 models. Heat pumps
on is manual are designed for heating pool water and
spas wiin e range 7ºC to 40ºC. The titanium water heat
exchangers fitted in ‘PPT’ Pro-Pacs are suitable for fresh and
salt water pools. Units wi e sux M are suitable for outdoor
pools operating in ambient temperatures above 10ºC, units
wi e sux MY are suitable for outdoor pools operating in
ambients -15ºC to 40ºC.
The units are fully packaged and should be sited outside in a
well ventilated area.
Oer features include integral safety devices to protect e
heat pump from internal and external faults. Indicator lamps
indicate operating mode. An adjustable ermostat controls
water temperature and a 6 minute timer is incorporated to
prevent compressor short cycling. A 12 hour delay timer is
incorporated into all machines, which aer a power interruption
or from initial start will prevent e machine compressor(s)
from starting for a 12 hour period. This feature is to protect
e compressors from liquid pumping which can cause internal
compressor damage.
HEALTH AND SAFETY WARNING
This appliance can be used by children from eight years and above and persons wi reduced
physical, sensory or mental capabilities or lack of experience and knowledge if ey have been
given supervision or instruction concerning e use of e appliance in a safe way and understand
e hazards involved. Children should not play wi e appliance. Cleaning and maintenance shall
not be made by children wiout supervision.
Disconnect from e mains supply and wait ree minutes before removing panels and
commencing work on is machine.
4 SD566252 ISSUE 51
PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

4. THE EXPANSION DEVICE and from ere, now at
normal pressure, it is returned to e evaporator and e
cycle starts again.
Note at during e cooling cycle is process is reversed.
THE HEAT PUMP CYCLE
3. THE CONDENSER where it is surrounded by e pool water.
e heat is given up to e cooler pool water and e now cold
refrigerant returns to its former liquid state but still under high
pressure from e compressor.
This pressure is released by passing e liquid rough –
Coecient of Performance
The eciency of a Heat Pump is usually called its ‘Coecient of
Performance’ – (C.O.P.) which is simply a ratio of heat output to
energy input, bo being expressed in kW. Thus a Heat Pump
absorbing 1 kW of electricity, collecting 4 kW of energy from e air,
and delivering 5 kW of heat to e pool water is said to have a C.O.P.
of 5:1.
Naturally, is ratio will vary according to e temperature of e water
and e ambient air.
1. THE EVAPORATOR collects e heat from e outside
ambient air, pre-heated by e sun. In e Calorex swimming
pool heat pumps, high volumes of outside air are drawn into
e unit by e fan expelled rough e evaporator fins. The
evaporator has liquid refrigerant passing rough it Which is at a
considerably lower temperature an e ambient air. Therefore
e air gives up its heat to e refrigerant which en vaporizes.
This preheated vapour now travels to –
2. THE COMPRESSOR where it is compressed and
upgraded to a much higher temperature. The hot vapour
now enters –
The Calorex Swimming pool heat pump provides ermodynamic
heating by means of a vapour compression cycle, (similar to at
employed in a conventional refrigerator), in addition to acting as an
active solar collector.
HOT GAS
COMPRESSOR
WATER
OUT
CONDENSED
REFRIGERANT
WATER
IN
HIGH PRESSURE SIDE
HEAT
EXCHANGER
EXPANSION
VALVE
COLD LIQUID
REFRIGERANT
LOW PRESSURE SIDE
EVAPORATOR
COOL GAS
AMBIENT AIR
5
SD566252 ISSUE 51

INSTALLATION.
1. SITING
NOTE: These units are not recommended for plant room installation.
1. Ensure heat pump on site is as ordered, i.e. model, electrical supply and
factory fitted options.
2. Inspect unit for damage, in particular inspect e evaporator (finned
side) to ensure at it is undamaged. (Minor indentations in e fins do
not affect performance). If severely damaged, endorse delivery note in
presence of e driver and send a recorded delivery letter to transport
company giving details.
3. Protect unit if installation is delayed.
4. Provide a firm level base capable of supporting operational weight of unit;
spread load on timber floor.
5. Ensure water cannot collect under unit - recommend units are installed
on plin 100mm above finished floor level and also to aid condensate
drainage.
6. Allow adequate clearance to service panels on unit; recommend 500mm
minimum (see installation drawings).
7. All Calorex heat pumps are by design as quiet as is practical, however
due consideration should be given to siting in order to fully exploit
is feature, i.e. ensure at e inlet and outlet grilles face away from
occupied premises.
8. Ensure loose debris such as leaves, grass cuttings, etc will not block air
inlet filters or grilles.
9. Consider protection from extreme weaer conditions.
IMPORTANT NOTE
Li e unit into place using a fork li truck, or similar liing device, if liing e unit from
above spreader bars must be used to avoid any pressure on e sides of e unit or
packing materials.
DO NOT PUSH OR DRAG THE UNIT ALONG THE GROUND.
6 SD566252 ISSUE 51
PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

Due consideration must be given to air flow, ie do not obstruct inlet or
outlet and ensure discharge air cannot recirculate to inlet (see figures
1 and 2)
Grill or apertures MUST comply wi figures (see Table 1)
< 3 m
CANOPY OR OBSTRUCTION
TOO CLOSE
> 3 m
TYPICAL OUTSIDE INSTALLATION
FIGURE 1 FIGURE 2
TYPICAL INSIDE OR PLANT ROOM INSTALLATION
(NOT RECOMMENDED FOR LONG DUCT RUNS).
THE PLANT ROOM IS NOT TO BE USED AS AN
OCCUPIED SPACE.
ADEQUATE
DUCTING
ADEQUATE
DUCTING
PRO-PAC
90/140
PRO-PAC
30/45/70
TABLE 1
MODEL Minimum Free Area m²
Inlet Discharge
Pro-Pac 30 0.59 0.25
Pro-Pac 45 0.98 0.42
Pro-Pac 70 1.19 0.52
Pro-Pac 90 1.731 0.84
Pro-Pac 140 2.138 1.04
2. AIR FLOW
TABLE 1
Required Free Areas to provide air flow to and from heat pumps when
installed on an enclosed area or where required to pass rough a wall
etc.
Free area is e available area rough which air can pass rough a
grille or louvres.
1. Note: If multiple units are installed in an enclosed area en e inlet free
areas required for each unit can be added togeer to form one inlet
aperture.
2. BUT discharge from each unit must be kept separate and must not be
incorporated into one common duct system.
3. 3. If e unit is installed in a plant room, e room should only be
accessible to auorised persons who are aquainted wi e operation of
e equipment and relevant safety precautions.
7
SD566252 ISSUE 51

The Calorex pool heat pump must be connected aer e filter in e
return pipe to e pool. If an existing heater is being retained, en e
Calorex should be connected between e filter and e oer heater.
(See Figures 3 & 4).
1. Calorex heat pumps have water inlet/outlet connections as follows:
2. Suitable breakable couplings should be installed local to heat pump.
3. If heat pump installed at lower level an pool water en isolation valves
should be fitted.
4. Drain valve or plug should be fitted to lower pipe to facilitate drain down
in winter period.
5. The condensation from e evaporator fins drains away rough holes in
e base of e unit. If desired, an optional factory fitted driptray wi 1½"
sink fitting can be fitted to allow e condensate to drain via 1½" domestic
waste piping. In is case it is necessary to ensure at e Calorex Heat
Pump is placed on a level plin so at e condensate can run away
wi adequate fall to waste ie ½" per foot minimum. A U trap should also
be incorporated into e pipework.
6. When e pipework installation is complete e pool pump should
be switched on and e system tested for leaks. Also check e filter
gauge to see at ere is not an excessive increase in back pressure. If
everying is en working normally e water circulating system is ready
to use.
7. Water circuit to and from unit to be capable of maintaining wiin specified
limits e rate of flow required by heat pump (see data sheet).
8. All pipework must be adequately supported wi allowance for
expansion/contraction especially wi plastic pipework.
9. It is recommended at when installing water system e last connections
to be made in e system should be e breakable couplings to avoid any
stresses on to e unit connections.
CORRECT DRAINAGE
FOR CONDENSATE ELBOW
'U' TRAP
SUPPLIED BY
CONTRACTOR
ADEQUATE FALL

MODEL Water in/out
connection size MODEL Water in/out connection size
- - Pro-Pac PPT30M/MY 2" UNION SOCKET
Pro-Pac 45 1½ BSPM Pro-Pac PPT45M/MY 2" UNION SOCKET
Pro-Pac 70 1½ BSPM Pro-Pac PPT70M/MY 3" BSPM
Pro-Pac 90 1½ BSPM Pro-Pac PPT90M/MY 3" BSPM
Pro-Pac 140 2" BSPM Pro-Pac PPT140M/MY 4" BSPM
3. PLUMBING
8 SD566252 ISSUE 51
PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

IMPORTANT
1. All pool purifying devices and chemical injection systems to be fitted
down stream of heat pumps unless installation is as per filter dosing (see
figure 3).
This includes e practice of dosing chemicals direct into skimmer basket,
which results in concentrated corrosive liquids passing over vulnerable metal
components.
2. Water quality must be maintained as follows:
3. Maximum pressure of water in heat pump circuit should not exceed 3 kg/cm² (50 psi).
pH 7.2 - 7.8
Total Alkalinity 80 - 120 ppm as CaCO3
Total Hardness 150 - 250 ppm as CaCO3
Total dissolved solids 1000 Max ppm
Saline Water (Titanium Condenser) 35,000 Max ppm
Saline Water (Cupro Nickel Condenser) 8,000 Max ppm
Chlorine - free Cl Range 1.0 - 2.0 ppm Domestic
Chlorine - free Cl Range 3.0 - 6.0 ppm Commercial
Ozone 0.9 Max ppm
Bromine 2 - 5 ppm
Baquacil 25 - 50 ppm
Aquamatic Ionic Purifier Max 2 ppm Copper
9
SD566252 ISSUE 51

POOL WATER SCHEMATIC
FILTER
FLOW SETTING
PRESSURE GAUGES
METHOD
PUMP
POOL
NON
RETURN
VALVE
SANITISER OR
CHEMICAL DOSING
POSITION AFTER
CALOREX
(STANDARD)
CALOREX
ENSURE POOL FILTRATION PUMP SELECTION ALLOWS FOR ALL SYSTEM RESISTANCE
OR LOOP
FLOW
SETTING
FLOW METER
METHOD
VALVE
VALVE
ISOLATING
B
ISOLATING
A
VALVE C
BYPASS VALVE
(LOCKING GATE VALVE TYPE)
AUX
HEATER
IF FITTED
FLOW METER METHOD (SEE FIG 3.)
Ensure isolation valves ‘A’ and ‘B’ and bypass valve ‘C’ are fully open.
Close e bypass valve until e flow light at is positioned on e
heat pump console illuminates and en close it slightly more to allow
for flow loss due to a dirty filter. Remove handle and lock off valve ‘C’.
Alternatively a water flow meter can be installed. See data sheets for
flow rates.
The Pro-Pac is fitted wi a water flow switch which inhibits e
operation of e machine when e minimum water flow is inadequate.
Adjust e water flow rate rough e heat pump until e green
Water Flow OK lamp on e machine console is illuminated. An
adequate water flow rate has now been achieved.
Fig 3
4. DETERMINING WATER FLOW
10 SD566252 ISSUE 51
PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

5.0 ELECTROLYTIC CORROSION IN SWIMMING POOLS
Electrolytic corrosion will occur when dissimilar metals at are in contact wi
each oer create a potential difference between emselves. Sometimes
separated by a conductive substance known as an electrolyte, e dissimilar
metals will create a small voltage (potential difference) at allows e ions of
one material to pass to e oer.
Just like a battery, ions will pass from e most positive material to e more
negative material.
Anying more an 0.3 volts can cause e most positive material to degrade.
A swimming pool wi its associated equipment can create is effect. The pool
water being an ideal electrolyte and components of e filtration circuit, heating
system, steps, lights etc providing e dissimilar metals needed to complete e
circuit.
Whilst ese small voltages are rarely a safety reat, ey can create premature
failure rough corrosion. Not dissimilar to corrosion rough oxidation,
electrolytic corrosion can cause complete failure of a metallic material in a very
short period of time.
In order to prevent is type of corrosion all metallic components in contact wi
swimming pool water should be bonded togeer using 10mm² bonding cable.
This includes non-electrical items such as metal filters, pump strainer boxes,
heat exchangers, steps and handrails. It is highly recommended at bonding
be retrofitted to existing pools, which may not be protected by is system.
11
SD566252 ISSUE 51

5.1 ELECTRICAL (MACHINE WIRING AND SUPPLY)
SEE FIG. 4,5, AND 6 FOR PREFERRED METHOD
The cable supplying electricity to a machine wi a given load must
increase in cross sectional area (C.S.A.) as e leng increases in order
at e voltage drop wiin e cable does not exceed recommended
limits. Cable sizing should be calculated by an appoved electrician. All
electrical work to be carried out in accordance wi I.E.E. standards,
latest issue, or local codes of practice as applicable.
The machine should be installed in accordance wi EMC2004/108/EC.
Protected supply to incorporate fuses or motor type circuit breakers
(Type C) to specified rating, (see Data Sheet). H.R.C. fuses are
recommended. An isolator which disconnects all poles must be fitted
wiin 2m and in sight of machine.†
All units must be correctly eared/grounded. An ear leakage trip of
e current operating type (30mA) is recommended to be fitted to is
heat pump and any associated equipment. When fitting recommended
ear leakage trip, to avoid nuisance tripping, e machine should be
connected to its own 30mA trip separate from any oer associated
equipment.
Inconsistent electrical supply
The following limits of operation must not be exceeded if Calorex
machines are to be guaranteed eier in performance or warranty
terms:
Voltage
MaximumMinimum
440V360VThree-phase machines (EU)
52.5Hz47.5HzCycle frequency (50Hz)
253V187VThree phase machines
(60Hz)
63Hz57.0HzCycle frequency (60Hz)
This voltage must be made available at e heat pump whilst running.
† Note e isolator must have a minimum of 3mm air gap when turned
off.
NOTE: All machines are fitted wi a phase protection relay and will not
run if e phases are not connected in correct order (phase sequence)
or if e supply voltage is 15% less an e nominal voltage. (415V for
3N~ 50Hz). The lamp on e phase rotation relay, situated in e electric
box, is illuminated when e phases are correctly connected and e
voltage is sucient. The undervoltage protection feature is not present
in phase protection relays fitted in 220V 3~ 60Hz machines.
When e machine is started for e first time it is vital at e 12 hour
delay incorporated into e compressor is allowed to occur. This delay
prevents damage to e compressor which would be expensive to
repair. Aer is initial start up e machine can be turned on and off by
use of e standby switch. It should be noted however at when on
standby e machine is still live.
12 SD566252 ISSUE 51
PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

Interlock
All units have interlock circuit incorporated in control circuit, brought out
to two terminals. These terminals are shorted out for factory testing.
The interlock may be used to control e heat pump from a remote
location or a built in flow switch.
On site shorting loop is to be removed and two wires taken to pair of
volt free contacts in water pump starter/contactor/relay or flow switch
so at e heat pump cannot operate unless water pump is operating
(see figs 5 and 6).
RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP WITH SINGLE
PHASE WATER PUMP
Fig. 5
L
N WATER PUMP MORE THAN
¾ HP SINGLE PHASE
SINGLE PHASE
SUPPLY TO SUIT
CAPACITY OF WATER
PUMP
L N
L N L
N L
4 POLE N/O STARTER WITH
OVERLOAD AND 230V 50Hz COIL
RATED TO SUIT WATER PUMP
N
L1 L2 L3 N
5
CALOREX HEAT PUMP
THREE PHASE
INTERLOCK
12346
SWITCHED FUSE ISOLATOR
WITHIN 2m OF HEAT PUMP AND
SIZED IN ACCORDANCE WITH
DATASHEET
7 9
811
10
Fig. 4
LOCATION OF MAINS INPUT AND EXTERNAL INTERLOCK TERMINALS
N L1 L2 L3
D209450 ISS 1
REMOVE SERVICE PANEL
(1/4 TURN FASTENERS)
MAINS SUPPLY IN
21
0 1
N L1 L2 L3
D209450 ISS 1
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15
16
17
SOFT
START SMART
CLOCK FLOW SWITCH
18
*OUTSIDE FAULT CIRCUIT
(ONLY ON Y MACHINES
WITHOUT TITANIUM
CONDENSERS)
*INTER
LOCK
13
SD566252 ISSUE 51

RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP WITH SINGLE
PHASE WATER PUMP
Fig. 5
L
N WATER PUMP MORE THAN
¾ HP SINGLE PHASE
SINGLE PHASE
SUPPLY TO SUIT
CAPACITY OF WATER
PUMP
L N
L N L
N L
4 POLE N/O STARTER WITH
OVERLOAD AND 230V 50Hz COIL
RATED TO SUIT WATER PUMP
N
L1 L2 L3 N
5
CALOREX HEAT PUMP
THREE PHASE
INTERLOCK
12346
SWITCHED FUSE ISOLATOR
WITHIN 2m OF HEAT PUMP AND
SIZED IN ACCORDANCE WITH
DATASHEET
7 9
811
10
Fig. 4
LOCATION OF MAINS INPUT AND EXTERNAL INTERLOCK TERMINALS
N L1 L2 L3
D209450 ISS 1
REMOVE SERVICE PANEL
(1/4 TURN FASTENERS)
MAINS SUPPLY IN
21
0 1
N L1 L2 L3
D209450 ISS 1
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15
16
17
SOFT
START SMART
CLOCK FLOW SWITCH
18
*OUTSIDE FAULT CIRCUIT
(ONLY ON Y MACHINES
WITHOUT TITANIUM
CONDENSERS)
*INTER
LOCK
L1
L2 WATER PUMP
THREE PHASE
L1 L2 L3 N
5
CALOREX
HEAT PUMP
THREE PHASE
THREE PHASE
SUPPLY TO SUIT
CAPACITY OF
WATER PUMP
L3 L1
L3 L2 L
4 POLE N/O STARTER WITH
OVERLOAD AND 230v 50Hz COIL
RATED TO SUIT WATER PUMP
L1
L3
L2
N
RECOMMENDED ELECTRICAL INSTALLATION FOR CALOREX HEAT PUMP
WITH THREE PHASE WATER PUMP
Fig. 6
12 3 47
6
SWITCHED FUSE ISOLATOR WITHIN
2m OF HEAT PUMP AND SIZED IN
ACCORDANCE WITH DATA SHEET
INTERLOCK
9
811 10
14 SD566252 ISSUE 51
PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

ELECTRICAL CIRCUIT DIAGRAMS
MCB SETTINGS
CONTROL
2.5A
COMPRESSOR FAN
0.8A22.9A
6 (N/O)
4 (N/O)
2 (N/O)
5
3
1
6 (N/O)
4 (N/O)
2 (N/O)
5
3
1
6 NO
4 NO
2 NO
5
3
1
(COM)
(N/O)
(N/O)(COM)
(N/O)
(COM)
(N/C)
5
(COM)
(N/O) (N/C)
(N/O)
(N/O)
(COM)
H (N/O)
(N/O) L H (N/C)
12 NC
A2
A2
A1
A1
2221
(N/C)
(N/C)
TB
TB
FAN THERMAL CUT OUT
FAN CIRCUIT BREAKER
TRIP / OFF = BREAK CONTACT
5
3
1
6 (N/C)
4 (N/C)
2 (N/C)
TRIP / OFF = BREAK CONTACT
COMP CIRCUIT BREAKER
5
3
1
6 (N/C)
4 (N/C)
2 (N/C)
(N/C)
(COM)
C
L(N/O)
H
DEFROST
STAT
(BREAKS TO
'H' ON TEMP
FALLING)
FAN MCB AUX BLOCK : ALARM
TRIP = BREAK CONTACT
COMPRESSOR MCB
AUX BLOCK : ALARM
TRIP = BREAK CONTACT
(N/C)
(N/C)
95
96
95
96
CONTROL
MAINS LIGHT
L3 L2 L1 CIRCUIT BREAKER
L1
L2
L3
11 COM
14 NO
PHASE
ROTATION RELAY
STARTER OR
EXTERNAL
FLOW SWITCH
INTERLOCK TERMINALS
SOFT START
THERMAL
O/LOAD &
FAULT LIGHT
IF FITTED
HP SWITCH
LP SWITCH
(BREAKS TO H ON
PRESSURE FALLING)
C (COM)
C (COM)
(N/C) L FAULT
LIGHT
(RUN)
1
23
(STANDBY)
STANDBY
SWITCH
1 (L)
10 11
6
SENSOR
4
OUT
1DIG STAT 1 STAGE
MAKES 6 TO 4 ON TEMP FALLING
98
2 (N)
SMART CLOCK
FEED TERMINALS
COMPRESSOR
MOTOR
PROTECTOR
A
B
WATER
FLOW
SWITCH
RELAY
(R1)
7
4
FLOW OK LIGHT
A1
A2
RELAY (R2)
14
11
DEFROST
LIGHT
FAN
CONTACTOR
COMP
(U1)
(V1)
(W1)
HEATER
(NC)
COMP AUX
CONTACTOR
DELAY TIMER 2
12 HOUR
DELAY TIMER 1
A1 A2
15 18
(BREAKS TO L ON
PRESSURE RISING)
NEUTRAL
7
6
11
10
Pro-Pac 30BM THREE PHASE 400V 3 N~ 50Hz
15
SD566252 ISSUE 51

CONTROL
2.5A
MCB SETTINGS
COMPRESSOR FAN
1.1A23.8A
LIQUID LINE SHUT OFF VALVE
FAN CIRCUIT BREAKER
TRIP / OFF = BREAK CONTACT
5
3
1
6 (N/C)
4 (N/C)
2 (N/C)
COMP CIRCUIT BREAKER
TRIP / OFF = BREAK CONTACT
5
3
1
6 (N/C)
4 (N/C)
2 (N/C)
(N/C)
(COM)
C
L(N/O)
H
(BREAKS TO 'H' ON
TEMP FALLING)
DEFROST
STAT
FAN MCB AUX BLOCK : ALARM
TRIP = BREAK CONTACT
COMPRESSOR MCB AUX BLOCK : ALARM
TRIP = BREAK CONTACT
6 (N/C)
4 (N/C)
2 (N/C)
CONTROL CIRCUIT
BREAKER
5
3
1
TRIP / OFF = BREAK CONTACT
12 (N/C)
L1
L2
L3
11 (COM)
14 (N/O)
PHASE
ROTATION RELAY
MCB CONTACTS / MCB ALARM CONTACTS / MCB AUX CONTACTS SHOWN WITH
CIRCUIT BREAKER MANUALLY SWITCHED TO THE ON CONDITION
WATER FLOW SWITCH CONTACTS SHOWN WITH WATER FLOW AT MAXIMUM RATE
ALL OTHER CONTACTS SHOWN IN DE-ENERGISED STATE BUT WITH REFRIGERATION
CIRCUIT FULLY CHARGED
WHERE CONTACTS ARE MARKED (N/O) OR (N/C) ON CIRCUIT DIAGRAM ABOVE
CONDITIONS APPLY
6 (N/O)
4 (N/O)
2 (N/O)
5
3
1
6 (N/O)
4 (N/O)
2 (N/O)
5
3
1
(COM)
(N/O)
(N/O)(COM)
(N/O)
(COM)
(N/C)
5
(N/C)
(N/C)
H (N/O)
(N/O) L H (N/C)
A2
A2
A1
A1
2221
(N/C)
(N/C)
TB
TB
FAN THERMAL
CUT OUT
95
96
MAINS LIGHT
L3 L2 L1
STARTER OR
EXTERNAL
FLOW SWITCH
INTERLOCK TERMINALS
SOFT START
THERMAL O/LOAD
& FAULT LIGHT IF
FITTED
HP SWITCH
(BREAKS TO L ON
PRESSURE RISING)
LP SWITCH
(BREAKS TO H ON
PRESSURE FALLING)
95
96
C (COM)
C (COM)
(N/C) L
FAULT LIGHT
1 (L)
10 11
6
SENSOR
4
OUT 1 DIG STAT 1 STAGE
MAKES 6 TO 4 ON TEMP FALLING
98
SMART CLOCK
2 (N)
FEED TERMINALS
NEUTRAL
COMPRESSOR
MOTOR
PROTECTOR
A1
A2
RELAY (R2)
14
11
DEFROST
LIGHT
FAN
CONTACTOR
COMP
(U1)
(V1)
(W1)
HEATER
(NC)
COMP AUX
CONTACTOR
DELAY
TIMER 2
12 HOUR
DELAY TIMER 1
A1 A2
15 18
(N/O)
WATER FLOW SWITCH AB
RELAY (R1)
FLOW OK LIGHT
1 (COM)
[STANDBY] (N/C) 3
[RUN] (N/O) 2 STANDBY
SWITCH
(N/O) 4
1 (N/C)
(COM) 7
6463
(NO)
COMP AUX
Pro-Pac 45BM THREE PHASE (400V 3 N~ 50Hz)
16 SD566252 ISSUE 51
PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

CONTROL
2.5A
FAN
3.3A
MCB SETTINGS
COMPRESSOR
46.8A
MCB CONTACTS / MCB ALARM CONTACTS / MCB AUX
CONTACTS SHOWN WITH CIRCUIT BREAKER MANUALLY
SWITCHED TO THE ON CONDITION
WATER FLOW SWITCH CONTACTS SHOWN WITH WATER
FLOW AT MAXIMUM RATE
ALL OTHER CONTACTS SHOWN IN DE-ENERGISED STATE
BUT WITH REFRIGERATION CIRCUIT FULLY CHARGED
WHERE CONTACTS ARE MARKED (N/O) OR (N/C) ON
CIRCUIT DIAGRAM ABOVE CONDITIONS APPLY
FAN CIRCUIT BREAKER
TRIP / OFF = BREAK CONTACT
5
3
1
6 (N/C)
4 (N/C)
2 (N/C)
COMP CIRCUIT BREAKER
TRIP / OFF = BREAK CONTACT
5
3
1
6 (N/C)
4 (N/C)
2 (N/C)
(N/C)
(COM)
C
L(N/O)
H
(BREAKS TO 'H' ON
TEMP FALLING)
DEFROST
STAT
FAN MCB AUX BLOCK :
ALARM
TRIP = BREAK CONTACT
COMPRESSOR MCB
AUX BLOCK : ALARM
TRIP = BREAK CONTACT
6 (N/C)
4 (N/C)
2 (N/C)
CONTROL CIRCUIT
BREAKER
5
3
1
TRIP / OFF = BREAK CONTACT
LIQUID LINE SHUT
OFF VALVE
6 NO
4 NO
2 NO
5
3
1
6 (N/O)
4 (N/O)
2 (N/O)
5
3
1
(COM)
(N/O)
(N/O) (COM)
(N/O)
(COM)
(N/C)
5
(N/C)
(N/C)
H (N/O)
(N/O) L H (N/C)
12 (N/C)
A2
A2
A1
A1
2221
(N/C)
(N/C)
TK
TK
FAN THERMAL
CUT OUT
95
96
L3 L2 L1
L1
L2
L3
11 (COM)
14 (N/O)
PHASE
ROTATION RELAY
SWITCH
STARTER
OR
INTERLOCK
TERMINALS
FLOW
THERMAL
O/LOAD &
LIGHT IF
FITTED
FAULT
EXTERNAL
SOFT START
HP SWITCH
LP SWITCH
(BREAKS TO H ON
PRESSURE FALLING)
43
44
C (COM)
C (COM)
(N/C) L
FAULT LIGHT
1 (L)
10
11
6
4
OUT 1 DIG STAT 1 STAGE
MAKES 6 TO 4 ON TEMP FALLING
87
SMART CLOCK
2 (N)
FEED TERMINALS
COMPRESSOR
MOTOR
PROTECTOR
A1
A2
RELAY (R2)
14
11
DEFROST
LIGHT
FAN
CONTACTOR
COMP
(U1)
(V1)
(W1)
HEATER
(N/C)
COMP AUX
CONTACTOR
DELAY TIMER 2
12 HOUR
DELAY TIMER 1
A1 A2
15 18
(BREAKS TO L ON
PRESSURE RISING)
(N/O)
WATER FLOW
SWITCH A B
RELAY (R1)
FLOW OK LIGHT
1 (COM)
[STANDBY] (N/C) 3
[RUN] (N/O) 2
STANDBY
SWITCH
(N/O) 4
1 (N/C)
(COM) 7
1413
(N/O)
COMP AUX
MAINS LIGHT
SENSOR
Pro-Pac 45EM THREE PHASE (220V 3~ 60Hz)
17
SD566252 ISSUE 51

CONTROL
2.5A
MCB SETTINGS
COMPRESSOR FAN
2.2A36.8A
MCB CONTACTS / MCB ALARM CONTACTS / MCB AUX CONTACTS SHOWN WITH
CIRCUIT BREAKER MANUALLY SWITCHED TO THE ON CONDITION
WATER FLOW SWITCH CONTACTS SHOWN WITH WATER FLOW AT MAXIMUM
RATE
ALL OTHER CONTACTS SHOWN IN DE-ENERGISED STATE BUT WITH
REFRIGERATION CIRCUIT FULLY CHARGED
WHERE CONTACTS ARE MARKED (N/O) OR (N/C) ON CIRCUIT DIAGRAM ABOVE
CONDITIONS APPLY
TRIP / OFF = BREAK CONTACT
CIRCUIT BREAKER
TRIP / OFF = BREAK CONTACT
CIRCUIT BREAKER
11 (N/O)
14 (COM)
(N/C)
(COM)
C
L(N/O)
H
(BREAKS TO 'H'
ON TEMP
FALLING)
(L) (N)
FAN MCB AUX
BLOCK : ALARM
TRIP = BREAK CONTACT
COMPRESSOR MCB
AUX BLOCK : ALARM
TRIP = BREAK CONTACT
LIQUID LINE SHUT OFF VALVE
6 (N/O)
4 (N/O)
2 (N/O)
5
3
1
6 (N/C)
4 (N/C)
2 (N/C)
5
3
1
6 (N/O)
4 (N/O)
2 (N/O)
5
3
1
6 (N/C)
4 (N/C)
2 (N/C)
5
3
1
6 (N/O)
4 (N/O)
2 (N/O)
5
3
1
(N/O)(COM)
(N/O)
(COM)
(N/C)
5
(N/O)
(N/O)
H (N/O)
(N/O) L H (N/C)
12 (N/C)
A2
A2
A1
A1
2221
(N/C)
TB
TB
FAN THERMAL
CUT OUT
95
96
CONTROL
MAINS LIGHT
L3 L2 L1 CIRCUIT BREAKER
L1
L2
L3
11 (COM)
14 (N/O)
PHASE
ROTATION RELAY
SWITCH
STARTER
OR
INTERLOCK
TERMINALS
FLOW
THERMAL
O/LOAD &
LIGHT IF
FITTED
FAULT
EXTERNAL
SOFT START
LP SWITCH
(BREAKS TO H ON
PRESSURE FALLING)
43
44
C (COM)
C (COM)
(N/C) L
FAULT LIGHT
1
10
11
6
SENSOR
4
OUT 1 DIG STAT 1 STAGE
MAKES 6 TO 4 ON TEMP FALLING
98
SMART CLOCK
2
FEED TERMINALS
NEUTRAL
A1
A2
RELAY (R2)
DEFROST
STAT
DEFROST
LIGHT
FAN
CONTACTOR
COMP
(U1)
(V1)
(W1)
HEATER
(NC)
COMP AUX
CONTACTOR
DELAY TIMER 2
12 HOUR
DELAY TIMER 1
A1 A2
15 18
HP SWITCH
(BREAKS TO L ON
PRESSURE RISING)
(N/O)
WATER FLOW
SWITCH A B
RELAY (R1)
FLOW OK LIGHT
1 (COM)
[STANDBY] (N/C) 3
[RUN] (N/O) 2 STANDBY
SWITCH
(N/O) 4
1 (N/C)
(COM) 7
1413
(NO)
COMP AUX
Pro-Pac 70BM THREE PHASE (400V 3N~ 50Hz)
18 SD566252 ISSUE 51
PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

MCB CONTACTS / MCB ALARM CONTACTS / MCB AUX CONTACTS SHOWN WITH CIRCUIT BREAKER MANUALLY
SWITCHED TO THE ON CONDITION
WATER FLOW SWITCH CONTACTS SHOWN WITH WATER FLOW AT MAXIMUM RATE
ALL OTHER CONTACTS SHOWN IN DE-ENERGISED STATE BUT WITH REFRIGERATION CIRCUIT FULLY CHARGED
WHERE CONTACTS ARE MARKED (N/O) OR (N/C) ON CIRCUIT DIAGRAM ABOVE CONDITIONS APPLY
MCB SETTINGS
23.8A2.5A
CONTROL COMPRESSORS
1.1A
FANS
STARTER OR
OUT 1
COMPRESSOR 1 HEATER
FAULT LIGHT
MAINS LIGHT
L1 L2 L3
N
14 (N/O)
95
(N/C) 96
95
(N/C) 96
FAN 1 MCB AUX BLOCK:ALARM
TRIP = BREAK CONTACT
TB FAN 1
THERMAL CUT OUT
FAN 2 THERMAL CUT OUT
TB
FAN 2 MCB AUX BLOCK:ALARM
TRIP = BREAK CONTACT
(N/C) TB
(N/C) TB
(N/C)
(N/C) COMPRESSOR 2
MOTOR PROTECTOR
COMPRESSOR 1 MOTOR PROTECTOR
EXTERNAL FLOW SWITCH
SOFT START THERMAL O/LOAD & FAULT LIGHT
IF FITTED
(COM) 1
RUN (N/O) 2 3 (N/C)
STANDBY
STANDBY
SWITCH
6 (COM)
1 (L)(N) 2
(N/O) 4
(N/C) 5
MAKES 4 TO 6 ON
TEMP FALLING DIGITAL STAT (1 STAGE)
5
PHASE
ROTATION
RELAY
CONTROL CIRCUIT
BREAKER
TRIP / OFF = BREAK CONTACT
1 3
2 (N/C) 4 (N/C) 6 (N/C)
L1 L2
L3
11 (COM)
12 (N/C)
9 (L)(N) 8
SMART CLOCK
FEED TERMINALS
AB
4 (N/O)
1 (N/C)
6 (N/O)
3 (N/C)
SENSOR
10 11
(COM) 7
(COM) 9
RELAY (R2)
(COM) C (N/O) H L (N/C)
DEFROST
BREAKS TO 'H' ON
AB
(N/C) 1
(N/O) 4 7 (COM)
RELAY (R3)
DEFROST LIGHT
B
B
1 (N/C)
4 (N/O)
(COM) 7
3 (N/C)
6 (N/O)
(COM) 9
RELAY (R4)
7 (COM)
(N/O) 4
(N/C) 1
(COM) C
(N/O) H L
(N/C)
A
A
FRIDGE CCT 1
TEMPERATURE
FALLING
DEFROST
BREAKS TO 'H' ON
FRIDGE CCT 2
TEMPERATURE FALLING
RELAY (R5)
1 (N/C)
(COM) 7 4 (N/O)
53
(N/C) 54
COMP 1 MCB AUX BLOCK
TRIP / OFF = BREAK CONTACT
15 (COM)
18 (N/O)
16 (N/C)
DELAY TIMER (2)
A1A2
COMPRESSOR 1
CONTACTOR
A1A2
FAULT LIGHT
FRIDGE CCT 2
2
A2 A1
COMPRESSOR 2
CONTACTOR
(COM) 9
53 54 (N/C)
3 (N/C)
6 (N/O)
COMP 2 MCB AUX BLOCK
TRIP / OFF = BREAK CONTACT
15 (COM)
16 (N/C)
18 (N/O)
A1A2
95
(N/C) 96
COMP 2 MCB AUX BLOCK
TRIP = BREAK CONTACT
(COM) C
(N/O) L H (N/C)
HP SWITCH BREAKS TO ‘L’
ON PRESSURE RISING
(N/O) H L (N/C)
LP SWITCH BREAKS TO 'H' ON PRESSURE FALLING
AB
RELAY (R1) 15
(COM)
18 (N/O)
16 (N/C)
A1A2
1
3
5
(N/C) 2
(N/C) 4
(N/C) 6
FAN
1
DELAY TIMER (1)
(12 HRS)
FAN 1 CIRCUIT BREAKER
TRIP / OFF = BREAK CONTACT
1
3
5
(N/O) 2
(N/O) 4
(N/O) 6
A1A2
FAN 1 CONTACTOR
1
3
5
(N/C) 2
(N/C) 4
(N/C) 6
FAN
2
FAN 2 CIRCUIT BREAKER
TRIP / OFF = BREAK CONTACT
1
3
5
(N/O) 2
(N/O) 4
(N/O) 6
A1A2
FAN 2 CONTACTOR
1
3
5
(N/C) 2
(N/C) 4
(N/C) 6
COMP
1
COMPRESSOR 1 CIRCUIT BREAKER
1
3
5
(N/O) 2
(N/O) 4
(N/O) 6
COMPRESSOR 1
CONTACTOR
21 (AUX)(N/C) 22
TRIP / OFF = BREAK CONTACT
1
3
5
(N/C) 2
(N/C) 4
(N/C) 6
COMP
2
COMPRESSOR 2 CIRCUIT BREAKER
TRIP / OFF = BREAK CONTACT
1
3
5
(N/O) 2
(N/O) 4
(N/O) 6
COMPRESSOR 2
CONTACTOR
21 (AUX)(N/C) 22
COMPRESSOR 2 HEATER
10 11
7 6
FAULT LIGHT
FRIDGE CCT 1
1
95 96 (N/C)
COMP 1 MCB AUX BLOCK
TRIP = BREAK CONTACT
C (COM) L (N/O)
HP SWITCH BREAKS TO ‘L’
ON PRESSURE RISING
C (COM) H (N/O)
LP SWITCH BREAKS TO 'H'
ON PRESSURE FALLING
H (N/C)
L (N/C)
INTERLOCK TERMINALS
U1
V1
W1
U1
V1
W1
(6 MINS)
DELAY TIMER (3)
(7 MINS)
63 (AUX)(N/O) 64
FRIDGE CCT 2
VALVE COIL
(LIQUID LINE SHUT OFF)
(N/C)
WATER FLOW SWITCH
BREAKS ON WATER
FLOW RATE FALLING
(N/C) 1
(N/O) 4 7 (COM)
AB
RELAY (R6)
FLOW OK LIGHT
FRIDGE CCT 1
VALVE COIL
(LIQUID LINE SHUT OFF)
63 (AUX)(N/O) 64
FRIDGE CCT 2
(COM) C
FRIDGE CCT 1
Pro-Pac 90BM THREE PHASE (400V 3 N~ 50Hz)
19
SD566252 ISSUE 51

CONTROL
2.5A
MCB SETTINGS
FANS 1 & 2
2.2A
COMPRESSORS 1 & 2
30.7A
WHERE CONTACTS ARE MARKED (N/O) OR (N/C) ON CIRCUIT DIAGRAM
ABOVE CONDITIONS APPLY
ALL OTHER CONTACTS SHOWN IN DE-ENERGISED STATE BUT WITH
REFRIGERATION CIRCUIT FULLY CHARGED
WATER FLOW SWITCH CONTACTS SHOWN WITH WATER FLOW AT
MAXIMUM RATE
MCB CONTACTS / MCB ALARM CONTACTS / MCB AUX CONTACTS SHOWN
WITH CIRCUIT BREAKER MANUALLY SWITCHED TO THE ON CONDITION
INTERLOCK TERMINALS
PHASE
ROTATION
RELAY
STARTER OR
EXTERNAL FLOW SWITCH
SOFT START THERMAL
O/LOAD & FAULT LIGHT IF FITTED
FAULT
LIGHT
FAN 1 THERMAL
CUT OUT
FAN 2 THERMAL
CUT OUT
FAN 1 MCB
AUX BLOCK : ALARM
FAN 2 MCB
AUX BLOCK : ALARM
TRIP = BREAK CONTACT
COMP 1 MCB AUX BLOCK
TRIP / OFF = BREAK CONTACT
CONTROL CIRCUIT
BREAKER
L3
L2
L1
FRIDGE CCT
2
FRIDGE CIRCUIT 1
COMP HP SWITCH (BREAKS TO 'L' ON PRESSURE RISING)
FRIDGE CIRCUIT 1
COMP LP SWITCH (BREAKS TO 'H' ON PRESSURE FALLING)
FAULT LIGHT
OUT 1
MAINS LIGHT
N
14 (N/O)
96
(N/C) 95
96
(N/C) 95
TB
TB
(N/C) TB
(N/C) TB
(COM) 1
RUN (N/O) 2 3 (N/C)
STANDBY
STANDBY SWITCH
6 (COM)
1 (L)(N) 2
(N/O) 4
(N/C) 5
MAKES 4 TO 6 ON TEMP FALLING DIGITAL STAT ( 1 STAGE)
5
TRIP / OFF = BREAK CONTACT
1 3
2 (N/C) 4 (N/C) 6 (N/C)
L1 L2 L3
11 (COM)
12 (N/C)
9 (L)(N) 8
SMART CLOCK
FEED TERMINALS
AB
4 (N/O)
1 (N/C)
6 (N/O)
3 (N/C)
SENSOR
10 11
(COM) 7
(COM) 9
RELAY (R2)
(COM) C (N/O) H L (N/C)
DEFROST STAT
BREAKS TO 'H' ON
AB
(N/C) 1
(N/O) 4 7 (COM)
RELAY (R3)
DEFROST LIGHT
B
B
1 (N/C)
4 (N/O)
(COM) 7
3 (N/C)
6 (N/O)
(COM) 9
RELAY (R4)
7 (COM)
(N/O) 4
(N/C) 1
(COM) C (N/O) H L (N/C)
A
A
FRIDGE CCT 1
TEMPERATURE FALLING
DEFROST STAT
BREAKS TO 'H' ON
FRIDGE CCT 2
TEMPERATURE FALLING
RELAY (R5)
1 (N/C)
(COM) 7 4 (N/O)
33
(N/C) 34
COMP 1 MCB AUX BLOCK
TRIP / OFF = BREAK
CONTACT
15 (COM)
18 (N/O)
16 (N/C)
DELAY TIMER (2)
A2A1
COMPRESSOR 1
CONTACTOR
A1A2
2
A1 A2
COMPRESSOR 2
CONTACTOR
(COM) 9
33 34 (N/C)
3 (N/C)
6 (N/O)
COMP 2 MCB AUX BLOCK
TRIP / OFF = BREAK CONTACT
15
(COM)
16 (N/C)
18 (N/O)
A1A2
44
(N/C) 43
COMP 2 MCB AUX BLOCK
TRIP = BREAK CONTACT
(COM) C (N/O) L H (N/C)
FRIDGE CCT 2 : HP SWITCH
BREAKS TO 'L' ON PRESSURE RISING
(COM) C (N/O) H L (N/C)
FRIDGE CCT 2: LP SWITCH
BREAKS TO 'H' ON PRESSURE FALLING
AB
RELAY (R1)
15 (COM)
18 (N/O)
16 (N/C)
A1A2
1
3
5
(N/C) 2
(N/C) 4
(N/C) 6
FAN
1
DELAY TIMER (1)
(12 HRS)
FAN 1 CIRCUIT BREAKER
TRIP / OFF = BREAK CONTACT
1
3
5
(N/O) 2
(N/O) 4
(N/O) 6
A2A1
FAN 1 CONTACTOR
1
3
5
(N/C) 2
(N/C) 4
(N/C) 6
FAN
2
FAN 2 CIRCUIT BREAKER
TRIP / OFF = BREAK CONTACT
1
3
5
(N/O) 2
(N/O) 4
(N/O) 6
A2A1
FAN 2 CONTACTOR
1
3
5
(N/C) 2
(N/C) 4
(N/C) 6
COMP
1
COMPRESSOR 1 CIRCUIT BREAKER
1
3
5
(N/O) 2
(N/O) 4
(N/O) 6
COMPRESSOR 1
CONTACTOR
21 (AUX)(N/C) 22
TRIP / OFF = BREAK CONTACT
1
3
5
(N/C) 2
(N/C) 4
(N/C) 6
COMP
2
COMPRESSOR 2 CIRCUIT BREAKER
TRIP / OFF = BREAK CONTACT
1
3
5
(N/O) 2
(N/O) 4
(N/O) 6
21 (AUX)(N/C) 22
COMPRESSOR 2 HEATER
10 11
7 6
FAULT LIGHT
FRIDGE CCT 1
44 43 (N/C) C (COM) L (N/O)
C (COM) H (N/O)
1
H (N/C)
L (N/C)
L1
L2
L3
L1
L2
L3
(6 MINS)
DELAY TIMER (3)
(7 MINS)
13 (AUX)(N/O) 14
FRIDGE CCT 2
VALVE COIL
(LIQUID LINE SHUT OFF)
(N/C)
WATER FLOW SWITCH
BREAKS ON WATER FLOW RATE FALLING
(N/C) 1
(N/O) 4 7 (COM)
AB
RELAY (R6)
W1
W1
V1
V1
U1
U1
FLOW OK LIGHT
FRIDGE CCT 1
VALVE COIL
(LIQUID LINE SHUT OFF)
COMPRESSOR 1 HEATER
13 (AUX)(N/O) 14
COMPRESSOR 2
CONTACTOR
TRIP = BREAK CONTACT
Pro-Pac 140BM THREE PHASE (400V 3 N~ 50Hz)
20 SD566252 ISSUE 51
PR0-PAC SYSTEM OWNER INSTALLATION MANUAL